Double Distribution Capacity
Client:
Buyers Products Company
Industry:
Industrial
Solution:
Distribution Systems Integration
Buyers Products Company is a truck, trailer and snow and ice equipment manufacturer with a facility that had been built in 2002 to process 225 orders per day, with a volume that had grown to up to 400 per day.
Challenge
- Buyers Products was using a facility built in 2002 to process 225 orders per day, with actual volume growing to almost double
- Operator labor was high with manual tasks
- Process requiring manual picking and routing orders between areas created congestion and caused errors
- Shipping area frequently bottlenecked due to space constraints
Solution
- DLN designed and installed a facility to double capacity and automate manual tasks, with ergonomic decanting, goods to person picking and packing areas
- Dual purpose routing / shipping sorter with order consolidation lanes and LTL parcel shipping lanes
- Multi-level design and spiral conveyors maximized footprint
- OSR shuttle system to improve order flow
Results
- System incrementally scaled over time
- Order orchestration solution would determine box sizing based on dimensions and weights led to efficient packing
- Parallel processing solved complexity of bringing orders to shipping
- Order capacity doubled
- Technology provided data for fast decision-making
